Process Engineer - Machining, Maintenance, Refractory

The Process Engineer role supports machining, maintenance, and refractory operations at the Woodstock, IL facility. The position focuses on continuous improvement, troubleshooting, and leading engineering and capital work to strengthen safety, quality, productivity, and cost competitiveness.

Key Responsibilities

• Drive process improvements across maintenance, refractory, and machining operations to improve safety, product quality, manufacturing yield, throughput, and overall operational efficiency.
• Lead continuous improvement efforts using Lean Manufacturing, Six Sigma, and structured problem-solving approaches to reduce variation, remove waste, and improve performance.
• Troubleshoot manufacturing challenges with production teams by reviewing process data, identifying root causes, and deploying sustainable corrective and preventive actions.
• Manage engineering and capital projects from investigation and cost estimation through financial justification, installation, implementation, and startup, coordinating with internal groups and external contractors.
• Support new equipment and process development by partnering with Engineering and Operations to introduce new components, materials, technologies, and manufacturing methods.
• Create process standards and performance measures, including standard operating procedures, work instructions, process control plans, and operational KPIs to support consistency and measurable results.
• Promote a continuous improvement culture by coaching and collaborating with cross-functional teams, removing obstacles, and recognizing achievements that improve operational performance.

Required Qualifications

• Bachelor’s degree in Engineering or a related field.
• 3+ years of experience improving processes in a manufacturing environment.
• Experience with Lean Manufacturing and problem-solving methodologies including Kaizen, 5S, and Six Sigma.
• Knowledge of manufacturing processes, production equipment, workflow, plant layout, and assembly methods.
• Working knowledge of Statistical Process Control (SPC), PFMEA, process control plans, process flow diagrams, and part routings.
• Strong analytical, troubleshooting, communication, and cross-functional collaboration skills, with the ability to lead or participate in multiple improvement projects.
• Basic proficiency with 2D/3D CAD software.

Technologies and Tools

• Lean Manufacturing
• Six Sigma
• Kaizen
• 5S
• Statistical Process Control (SPC)
• PFMEA
• 2D/3D CAD software

Preferred Qualifications

• 5+ years of experience leading safety, quality, and process improvement initiatives in manufacturing.
• Experience with CNC programming and machining processes.
• Six Sigma Green Belt certification or higher from a recognized organization.
• Proven results applying Lean Manufacturing, continuous improvement, and value stream methodologies.
• Demonstrated project management experience, including leading Kaizen events or improvement projects.
• Experience with SolidWorks or Pro/ENGINEER (Pro/E).
• Proficiency with statistical analysis, flowcharting, and process mapping software.

Benefits

• Comprehensive health, dental, and vision benefits
• 401(k) plan with employer matching and profit sharing
• Company-paid life insurance
• Disability coverage
• Paid time off (PTO)

Role Details

• Location: Woodstock, IL (onsite)
• Schedule: Onsite
• Travel: Up to 10% to other Charter locations or vendors
• Work Authorization: Applicants must be authorized to work for any employer in the U.S. Charter Manufacturing is unable to sponsor employment visas at this time.

Compensation

USD 82,000 - 102,500 per year